I cut off the top right below the seam where it goes back out under the windows. I cut it at a decent angle, with the inside cut being much lower than the outside, as the roof piece extends inches below the top of the side piece. I cut across the roof in about the middle of the doors (I measured like 15 times, but don't remember it now)
Once I got the roof off, I drilled out the spotwelds holding the side piece to the roof piece. I then attached s5' 2"x2" 16ga angle to the bottoms of the sides of the roof, starting at the rear. I had to trim some of the angle to clear the windows, as the bottom of the sides of the roof piece have a slant to them (Which I transferred to the camper shell. I attached it with tek screws (5/16 drive, #10?, 3/4", self-tapping). At the front, I finished framing the sides, and framed the front with 1"x1" 16ga angle.
The gaps in the sides I filled with some 24g I had laying around. I am still not sure what I want to put here. Would like to make it openable for access to the bed. I filled in the front with some strips of 16g. Pics in a bit.
I was moving out of state the day I finished it, so I scabbed in a back window from a trailer. No pics because it was nasty. Have the parts now to put on the same window, but with a lift hinge. Had to do some nasty stuff with the back corners to get the support I wanted, but will re-do that.
Also have a slider window for the front that I will install.
I used funnoodles as the cab-cap gasket.
Moved the furthest forward roof support beam forward a couple inches.
Ended up having to hack in a bunch of finishes, since I was moving the next day. Have been here just over a year, with no access to a welder, so no work done on the cap. I'm gonna pull off the angle from the sides, cut it nicely, and weld it back on. I also have some more welding to do at the front where the roof meets the 16g I put across the front.
Then it's just a couple decisions as to the back window, and what I wanna do on the front of the sides.
more to come...
Beauty is in the eye of the jeepowner.